Castellated and cellular beams are custom designed for a
specific location on a specific project. The process by which
castellated and cellular beams are fabricated is similar, but not identical. Castellated beams are fabricated by using a computer operated cutting torch to cut a zigzag pattern along the web of a wide-flange section. The step-by-step process of manufacturing a castellated beam is presented in Figure 1-1. Once the section has been cut in the appropriate pattern (a), the two halves are offset (b). The waste at the ends of the beam is removed (c), and the two sections are welded back together to form the castellated section (d). A full or partial penetration butt weld is then typically made from one side of the web, without prior beveling of the edges if the web thickness is relatively small. A photograph of the manufacturing process of a castellated beam is shown in Figure 1-2. Cellular beams are fabricated in a similar manner using a nested semicircular cutting pattern. In order to achieve the repeating circular pattern, two cutting passes are required, as shown in Figure 1-3. The two cutting passes increase the handling of the steel during the manufacturing process; consequently, the time to produce a cellular beam is slightly greater than that of a castellated beam. The cuts are made in a circular pattern instead of the zigzag used for the castellated beams. The circular cutting produces additional waste as compared to castellated beams, as shown in Figure 1-3(b). Once the two cuts have been made, the two halves that have been created are offset and welded back together to form a cellular beam. A photograph of the manufacturing process of a cellular beam is presented in Figure 1-4.